ANI

NDUSTRI
ALTRAI
NINGREPORT
ON

SANGAM MI
LKPRODUCERCOMPANYLI
MITED
SANGAM DAI
RY-VADLAMUDI,
GUNTURDI
SRTI
CT,
ANDHRAPRADESH-522213.

Par
ti
alf
ulf
il
lmentofr
equi
rementsunderI
ndust
ri
alTr
aini
ng
submi
tted

Fort
heawar
dof

DI
PLOMAI
NCHEMI
CALENGI
NEERI
NG

JANI
LKUMARREDDY. 16096-
CH-
030

DEPARTMENTOFCHEMI
CALENGI
NEERI
NG
GOVERNMENTPOLYTECHNI
CFORMI NORI
TIES
Nal
lapadu,
Gunt
ur-522005.

30
 SANGAM DAIRY-VADLAMUDI
,
GUNTUR,
ANDHRAPRADESH-522213.

CERTI
FICATE

Thi sistocerti
fythatJ.ANILKUMARREDDY, i
stheStudent
ofGOVT. POLYTECHNI CFORMI NORITIESCOLLEGE, GUNTUR
studyi
ng"DI PLOMAI NCHEMI CALENGINEERI NG"hasunder gone
3mont hsindustri
altr
aini
nginMILKPOWDERPLANTof
SANGAM DAI RY.Forhis3monthsIndust
rialTrai
ningfrom t
he
06-03-2019t o05-06-2019duri
ngthi
speriodhisper f
ormance
wasf oundt obe

S/Shri
.C.PREMSAI
,
JEOFPOWDERPLANT,
SANGAM DAI
RY,
GUNTUR.

31
 ACKNOWLEDGMENT

Wesincerel
yt hankt oMr .
M.SAMPATHKUMAR( Princi
pal)
,
MssM. MAHALAKSHMI( HeadofChemi calDepar t
ment )
andourtrai
ningi nchargeMssJ.GOUTHAMI ,MrVI JAY
KUMARandal lthef acul
tyofourcol
legeforhelpingust o
Completeoursecondspel lt
rai
ning"
SUCCESSFULLY" .

Weexpr essourdeepsenseofgr aduatetothe

advisorofBoar dofAppr ent
iceTrai
ning( Chennai)and
Gov er
nmentPol ytechnicforMinori
ti
esf orgivingusthi
s
wonder fulopportunitytoundergotrai
ningi nthis
presti
giousor ganisation/Company.

Weareextremelygratefult oS/Shri.C.PREMSAI ,
JUNIORENGI NEERofPowderSect ion.Wef eelextreme
deli
ghtedinacknowl edgi
ngourgui desS/ ShriSUBBARAO,
i
nchargeofPowderSect ionandal lSenioroper ator
s,
Operators,f
orkeepingmeagi leandzeal oust hr
oughout
thecoursewor k.Wear edeeplyindebt edt othem forthei
r
val
uableencour agementandent husi ast
icper sonal
i
nterestduri
ngt heentir
ecourseoft histrai
ning

Your
ssi
ncer
ely
,
J.
ANILKUMARREDDY.

32
 Mi
lkPowderr
oduct
ionpl
ant

I
ntr
oduct
ion:

Today,theproductionofdriedmi l
ksandmilkproductshasbecome
anincreasingl
yimportantsegmentoft hedair
yindustry
.Drymilkprovi
desameansof
handl
ingt heexcessmi l
ksupplyinadai ryf
actoryduri
ngthefl
ushseason,whileint
he
l
eanseason,t hatmeantf ort
hepr oductionofdrymi l
kcanbedeliver
edtomar ketmi
lk.
Thus,drymi l
kmaybecal l
edt hebalancewheel ofthedai
ryi
ndustr
y

PowderPl
ant
s:

Therear
etwospr
aydry
erplantsi.
e.,
L&TandSTAI NCOhavi
nga
capaci
tyof12Metri
ctonand10Metr
ict
onsrespecti
vel
y.Int
hissect
ionmil
kisdri
edf
or
powderprepar
ati
on.

TheL&TmakeSpr
ayDr
yingUni
tConsi
stsofFol
lowi
ngEqui
pment
s:

 Fall
ingf i
lm ev apor ator( t
ripleeffect)withcapacit
yof6000lph.
 El
ev enpumps:
Mi lkpump -1
Concent ratepumps -3
Re- cir
culationpump -1
Condensat epumps -2
Vacuum pump -1
War m wat erpump -1
Spr aypondi nletpump -1
Spr aypondout l
etpump -2
 Onet ubul arpr e-
heat er .
 Twof eedbal ancet anksof2000l i
tscapacit
yeach.
 Airpre-heat er-40HPmot orisusedf orai
rsupply.
 Centrif
ugal atomizerat14, 500r pm.
 L&Tspr aydr ierof12MTcapaci t
y/day.
 Thet emper atureofai rusedf ordr yi
ngisaround175-185ºC.
 Theai rispr eheatedbyst eam t hroughacoi lheat
er.
 Theout lettemper at ureofhotai ris90-95ºC.

33
PumpsUsedi
nL&TPl
ant
:

Ty
peOfMot or& H.
P R.
P.M Maker
Pump
Concentr
ate 5 1420 ALFALAVAL
pump
Condensat
epump 5 1420 ALFALAVAL

Tubul
arheat
er 5 1420 HMT
pump
Preheat
erpump 3 1420 HMT

Warm water 7.
5 2875 NGEF
pump
Vacuum pump 20 1450 MAZDA

Suppl
yfan 40 1460 ABB

Conv
eyi
ngf
an 10 1430 ABB

Exhaustf
an 50 1440 ABB

Cool
i
ngf
an 1 2880 ABB

Rot
aryv
alv
es 0.
5 920 TT

Spr
aypond 10 2850 BEACON

Mi
l
kpump 7.
5 - -

At
omi
zermot
or F35 14500 NI
RO

St
ani
coUni
tConsi
stsoft
heFol
lowi
ngPar
ts:

 Falli
ngFil
m Ev aporatorwit
h4,500lphcapacity.
 Highheat erf
orheat i
ngofpr eheatedmilktopasteur
izat
iontemper
atur
e.
 Coiltypeairheaterforheati
ngofi nl
etairt
hatishotairgoesint
odrier
.
 Vacuum pump.
 Pressurespraynozzl etypeatomizer.
 Hi ghpressurepump- 100to140kg/ cm2.
 Staincospraydryingunitof10MT/ daycapacit
y.

34
PumpsUsedi
nSt
aincoPl
ant
:

Ty
peOfMotor&Pump H.
P R.
P.M Maker
GDpump(
1-17) 5 2830 ABB
GDpump(
mil
ktank) 7.
5 1400 ABB
GDpump(
feed) 3 2840 ABB
Rot
aryv
alv
e 0.
5 1390 KI
RLOSKAR
Bl
owt
hroughv
alv
e1 3 2850 ABB
Bl
owt
hroughv
alv
e2 3 2850 CG
Bl
owt
hroughv
alv
e3 5 2840 ABB
Hi
ghpr
essur
epump1 1300LPH 300 ABB
Hi
ghpr
essur
epump2 1300LPH 300 ABB
Vacuum pump(
singl
est
age) - - MAZDA
Vacuum pump 20 1450 CG
Spr
aypondpump 20 2860 JYOTHI
Suppl
yfanmot
or - 2710 ABB
Suppl
yfan 40 1470 ABB
Exhaustf
an 50 1470 ABB
Conv
eyi
ngf
an 10 2875 NGEF

Ev
apor
ati
onPl
ant
:

Ef
fect Nooft
ubes Di
amet
er Hei
ght(
mm)
1. 121 38 5480
2 73 38 5480
3. 65 38 5480

35
FeedPar
amet
ersofSki
m mi
l
k:

Fat
% -<0.
1
Aci
dit
y. -<0.
135t
o0.14
MBRT -<NLT5hr
s

FeedFl
owi
nEv
apor
ati
on&Spr
ayDr
yingPl
ant
-L&T:

Feedf
rom pr
ocessi
ngsect
ion(
4-5º
C)

Pr
eheat
ing(
40-
50º
C)

Bal
ancet
ank

Tubul
arheatexchanger(
82º
C)

Cal
andr
iaI(
78º
C/550mm)

Cal
andr
iaI
I(69º
C/600mm)

Cal
andr
iaI
II(
60º
C/650mm)

Mi
l
kconcent
rat
ioni
nfeedt
ank(
Baumer
eadi
ng–20t
o23)

Pumpi
ng

At
omi
zer(
14,
500r
pm)

Dr
yer
(Hotai
rtemper
atur
e175-
185º
C)

Cy
clonesepar
ator

Packagi
ng(
25kgbags)

36
FeedFl
owi
nEv
apor
ati
on&Spr
ayDr
yingPl
ant
-STAI
NCO:

Feedf
rom pr
ocessi
ngsect
ion(
4-5º
C)

Bal
ancet
ank

Condensor

Cal
andr
iaI
II
(60º
C)

Cal
andr
iaI
I(69º
C)

Cal
andr
iaI(
78º
C)

Hi
ghheat
er

Fl
ashv
essel

Cal
andr
iaI(
70º
C)

Cal
andr
ia-
B

Cal
andr
iaI
I(60º
C)

Cal
andr
iaI
II(
45º
C)

Mi
l
kconcent
rat
ioni
nfeedt
ank(
Baumer
eadi
ng–20t
o23)

3pi
stonpr
essur
epump

Spr
aynozzl
es

Dr
yer
(Hotai
rtemper
atur
e(175-
185º
C)

Cy
clonesepar
ator

Packagi
ng(
25kgbags)

37
St
art
ingPr
ocedur
eofEv
apor
ati
on&Spr
ayDr
yingPl
ant
:

 Checkl eaksi nthesy st

em byst art
ingonebyonepumpf rom tubul
arheatert
o
thi
rdcal andr i
a.
 Startvacuum pumpandal lowv acuum t obui
ldup.
 Startspr aypondi ncomi ngpump.
 Startwar m wat erpump.
 Startspr aypondout goingpump.
 Startvacuum pumpt obuil
d700±20mm/ Hgwi thi
n10-15mi nutes,
otherwise
checkf orv acuum l eakagesont heev aporat
ionplant
,tightenthepipel
ineunions
andcal andr iajoint s.
 Startpre- heaterpump.
 Starttubul arheat erpump.
 Startfi
rstcal andr iapump.
 Startsecondcal andr iapump.
 Startthirdcal andr iapump
 Startre-circulationpump.
 Opent her mocompr essorf orsteam (mi n7Kg/ cm2forchemi calcl
eaning,
min8- 12Kg/ cm2f orpr oducti
on) .
 Openst eam f ort ubul arheater
,sett hetemper atur
eofthepr oductinbetween,
78-82̊C
 Startfi
rstcondensat epump.
 Startsecondcondensat epump.

ShutDownPr
ocedur
e:

 St
oppr eheaterpump.
 Cl
osethest eam v alve.
 St
opcondensat epump.
 Af
tersetti
ngwat ertemper
atur
etot
henor
mal
,st
opt
hef
oll
owi
ng:
-Vacuum pump
-Spraypondi nl
et
-Spraypondout let
-War m waterpump
-Tubularheat erpump
-
Firsteff
ectpump
-Secondef fectpump
-Thirdeff
ectpump
-Re-cir
culat
ionpump

38
 I
mpor
atanceofCI
P:

 Useofcaust icisfordissol
v i
ngprotei
ndeposit
sanduseofnitr
icaci
di sf
or
di
ssolvingmilkstone
 Asacidwi l
lhardent heprot
einandmakei tver
ydiff
icul
ttodi
ssolv
e,forpr
oduct
s
contai
ningproteinthecleaningprocessshoul
dstar
twithcaust
icsoda.
 Steam pressureshouldber educedtoapproxi
matel
y75%ofnor malrunni
ng
condit
ions.

Cl
eani
ngPr
ocedur
e(CI
P):

 Fl
ushoutwi thtapwat ert i
l
ltheclearwat erisobtained.
 Hotwat erci rculati
onat75˚ cto82˚ cfor5mi n.
 Cleaningwi thni tr
icacidsoluti
on@ 2- 2.5% at70˚ c,re-
cir
culateacid
soluti
onf or30- 40mi nutesandr unt hroughallthepipelines.
 Drainoutaci dsol uti
on.
 Cleaningwi thcaust icsodasol ut
ion@ 2- 2.5% at70˚ c,
re-ci
rculateaci
d
soluti
onf or30- 40mi nutesandr unt hroughallthepipelines.
 Drainoutal kalisoluti
on.
 Giveabundantwat ertor emoveacidandal kal
inet r
acesinpl ant.
 Drainoutci rculatedwat er.
 Plantisreadyt otakethemi l
kforev aporati
on.

Cl
eani
ngI
nPl
ace:

What When How Cl

eaningAgent
s
Ev
aporat
ors i. Forever
y Caust
ic,hot
10hr water
i
i. Forever
y CI
P
48hr Caust
ic,
Nit
ri
c
i
i
i. Forever
y aci
d.
60days
Brush
Concentr
ati
onvats Forev
ery2hr Manual Soapoil
Dri
er,at
omizerwheel i
. Before
par
ts st
art
ingof Hotai
r
pr
oducti
on

39
 L&TEv
apor
ati
onandDr
yerPl
antPar
amet
ers:

Par
amet
ers Requi
red Obt
ained(
Avg)
St
eam pr
essur
e(Kg/
cm2) 12.
5 14-15
Vacuum (
Kg/
cm2) 0.
98 0.
98
3rdef
fectsepar
atort
emper
atur
e(°
C) 42 42-47
3rdef
fectcal
andr
iat
emper
atur
e(°
C) 60 58-60
2ndef
fectsepar
atort
emper
atur
e(°
C) 60 55-60
2ndef
fectcal
andr
iat
emper
atur
e(°
C) 69 62-67
1stef
fectsepar
atort
emper
atur
e(°
C) 69 68-71
1stef
fectcal
andr
iat
emper
atur
e(°
C) 78 78-82
Tubul
arHeat
er(
°C) 82-
90 82
Condensercol
d(°
C) 30 -
War
m wat
ert
emper
atur
e(°
C) 37-
40 35-40
Ther
mocompr
essor(
Kg/
cm2) 8-
12 10.
4-10.
6
Baumer
eadi
ng 14-
22 22
Dr
yeri
nlett
emper
atur
e(°
C) 175-
185 180-182
Dr
yerout
lett
emper
atur
e(°
C) 90-
95 88-89
Loadonat
omi
zer(
amp) 20-
25 30
Chamberv
acuum (
mm ofhg) -
5to-
8 -
5
Vat
schangedt
ime 2hr
s -
Moi
stur
e NMT3.
7% 3–3.
3%

Dr
yingPl
ant
:

Par
amet
er L&T STAI
NCO
I
nletai
rtemper
atur
e(º
C) 175t
o200 190t
o200
Outl
etai
rtemper
atur
e(º
C) 90t
o100 90t
o100
Concent
rat
efeedt
emper
atur
e(º
C) 54 55
At
omi
zerspeed(
rpm) 14400 -
Powderout
put(
kg/
hr) 550 450
Powdert
emper
atur
e(º
C) 35 35

40
St
aincoEv
apor
ati
onandDr
yerPl
antPar
amet
ers:

Par
amet
ers Requi
red Obt
ained(
Avg)
St
eam pr
essur
eKg/
cm2 12-
15 13-
15
Vacuum mm/
Hg 700 700
3rdef
fectseparatort
emper
ature 40-
57 43,
44
Flashvesselcalandr
iat
emperat
ure 50-
60 63,
64
2ndef
fectsepar
atort
emper
atur
e 50-
60 56,
57,
58
2ndef
fectcal
andr
iat
emper
atur
e 60-
70 -
1stef
fectsepar
atort
emper
atur
e 60-
70 69-70
Jacketcal
andr
iat
emper
atur
e 70-
80 65,
67,
70
1stv
apoursepar
ator(
vacuum mm/
Hg) 600 600
2ndv
apoursepar
ator(
vacuum mm/
Hg) 650 650
3rdv
apoursepar
ator(
vacuum mm/
Hg) 700 700
Hi
ghheat
er(˚
C) 85-
90 85
Ther
mocompr
essorKg/
cm2 5-
10 4.
1,4.
2,4.
6
Baumer
eadi
ng(
OBE) 20-
23 15,
21,
22
Dr
yeri
nlett
emper
atur
e 175-
200 180,
181,
182
Dr
yerout
lett
emper
atur
e 90-
100 88,
89
Chamberv
acuum m.m.wq G5 -
5,-
5
Vat
schangedt
ime 2hr
s -
Moi
stur
e NMT3.
7% 2.
9,3.
1,3.
2

41
Pr
epar
ati
onPr
ocedur
eforSpr
ayDr
yerPl
ant
:

 Checkwhet herthesy stem i

swel lcharged
 Checkwhet heralltheinstr
ument sar einoperati
ngcondi t
ionandwell
cal
ibr
at ed
 Checkal ltheut i
l
itysuppli
essuchasst eam,rawwat er,
softwater
,
compr essedai randpoweret c.
, areav ail
ablewithr
ightcondit
ions
 Checkal lthefandamper sposition
 Checkwhet herallthemot orsandpumpsar einoperati
ngconditi
on.
 Checkai rdistri
butorforit
spr operal ignment
 Checkat omi zerassembl y,l
ubricationoi ll
evelandcleanli
ness
 Posit
iont heai rf
il
terscarefull
yaf tercleaning
 Seethatal lsafetysystemsar eoper ati
onal
 Maintainpr opervacuum int hepl ant

St
art
ingPr
ocedur
e:

 Sett heoper ationt omanual posi ti

on
 Startther otar yv al veofcy clonesepar at ors
 Startthepowerconv ey i
ngandseet hecool ingf ani soperating
 Startthesuppl yai rf an
 Starttheexhaustf an5secondsaf t
ert hest ar t
ingofsuppl yfan
 Startthehammer sandst artbagf il
ters, fans, vi
br ators,et
c
 Starttheai rheat erandSt artt heat omi zerandcheckt helubricati
onsy st em and
theal i
gnmentf orpr operoper at i
on
 Startthef eedpumponwat erassoonast hedr y erout l
ettemper at
urer eaches
100t o105º C
 Adjustt heout letai rt emper atur eto100º Cbycont roll
i
ngwat erfeed
 Mai ntainthedr yingchamberv acuum int her angeof5mm ofHg
 Cyclonesepar atorsshoul dhav eabout130t o150mm pr essurediff
er ence
betweeni nl etandout let
 Startdehumi difyingsy stem f orconv ey ingai r
 Startcoolingandheat i
ngsy stem wi thv ibratorandsecondst ageofdr yingand
attainthepar amet erst ooper at etheseuni tsef fi
ci entl
y
 Tur nt hev alvet ot hepr oduct .Cont rol thef eedr at emanual l
yt omai ntainthe
desiredout l
ett emper atureasperpr oductandaspermoi sturerequirement
 Ifthemoi st urei stoohi gh,raiset heout lettemper at ur
eandi ftoolow, reducet he
outlettemper atur eandt urnt oaut ocont rolposi tion
 Checkt hepowdert emper atur eatt hepackagi ngsect i
on.

42
ShutDownPr
ocedur
e:

 Switcht hedryerfr
om pr oducttowat erwithoutwetti
ngt hedryerchamber
.
 After10mi nutesstopt hesteam supplyt otheairheaterandshutof ft
hef
eed
pumpandt heat omizer.
 Afterthedryerhasr eachedcloset oambi enttemperature,openthechamber
doorsl i
ghtl
yandst opt hesupplyfan.
 Closet hesupplyfandamperbet weenai rheateranddr y
ingchamberand
continuepowdersweepi ngoperation.
 Shutdownt herestofthesy stem andcloset hedryertoo.

PowderPl
antCl
eani
ng:

 Rinsewi t
hcoldwat erunti
lthewat errunsclean
 Causticcir
culati
oncausticsoluti
onf or30mi nwit
hof0.5%concentr
ati
onat
70ºCatapar tialvacuum of500mm Hg
 Hotwat erri
nseunt i
ltheunitrunsclear
 Acidcircul
ati
onf or30minwi thnitri
cacidof1.5%concentr
ati
onat65ºCat
parti
alvacuum
 Hotwat erri
nseat70ºCunt il
wat errunsclear&Neut
ral
izewit
h0.5%caust
ic
soda
 Hotwat erri
nseat70º Cfor10mi n

Nut
ri
ti
onalFact
sofMi
lkPowder(
100gms)
:

Energy 360K.cal
Fat 1.5g
Sugar 0g
Lactose 51.0g
Protein 36.0g
Miner al
s 7.5g
Sat
uratedFat tyAci
ds 1.02g
Cholesterol 6mg

43
THANKYOU

44